Vehicle component including basalt and method for making same

ABSTRACT

A vehicle component formed using a reinforcing mixture that includes a plurality of basalt fibers. According to one embodiment, the reinforced vehicle component could be formed by a method in which a vehicle component is provided for reinforcement, such as a vehicle panel that may be stamped from steel. Basalt fibers are mixed with a carrier that includes one or more of an epoxy or a glue. The mixture of basalt fibers and the carrier are applied to the vehicle panel. In one embodiment, for example, the mixture could be sprayed onto the vehicle panel for purposes of reinforcement.

RELATED APPLICATIONS

The present application is a continuation of U.S. Utility patentapplication Ser. No. 13/621,917, filed on Sep. 18, 2012, entitled“Vehicle Component Including Basalt and Method for Making Same,” whichis related to and claims priority U.S. Provisional Patent Application,Ser. No. 61/536,311, filed on Sep. 19, 2011, entitled “Vehicle ComponentIncluding Basalt and Method for Making Same.” To the extent not includedbelow, the subject matter disclosed in these applications is herebyexpressly incorporated into the present application in its entirety.

BACKGROUND AND SUMMARY

A basalt fiber offers many favorable qualities. For example, a basaltfiber generally offers a very strong material high tensile strength(e.g., 3200 MPa), high softening temperature (e.g., 1200 degreesCelsius), operating temperature typically from −260 to 760 degreesCelsius, low elongation modulus (e.g, 89 GPa), density (e.g., 2.7grams/cubic centimeter), high sound absorption coefficient (e.g., 0.95)and radiation proof lead equivalent (e.g., 0.0073 mm P b), highelectrical resistance and basalt is recyclable. Basalt is stronger thansteel, but is lighter with a weight about the same as aluminum. FIG. 1illustrates an exploded view of an example strand of pultruded basaltfiber.

Basalt has several favorable qualities compared to carbon fiber

-   -   Basalt is much cheaper than carbon fiber    -   Basalt is stronger than E-glass, and as strong as and cheaper        than S-glass.    -   Basalt has a very good tolerance to high and low temperature.    -   Higher electrical insulation value than E-glass.    -   Basalt is much more resistant to shattering than carbon. This        leads to a much more forgiving failure mode.    -   Basalt does not conduct electricity. Basalt does not induce        fields when exposed to high levels of RF energy, which means        there is no issue of Faraday cage effect. Basalt can be used in        high level RF fields without strange electrical issues happening        to the structure.    -   Basalt is transparent to microwave energy. Basalt does not        absorb microwave energy until it reaches around 800 F.    -   Basalt has high resistance to acid and alkali conditions

One focus of this application is to demonstrate how basalt fibermaterial can be used as reinforcement for steel panels, offer a built inroll cage system while building lighter and stronger vehicles. Thebasalt fiber offer extremely strong characteristics which can beharnessed and employed in the building of safer stronger productionvehicles. It is planned on accomplishing this build of vehicles usingbasalt by reinforcing the existing panels on the inside with basaltfiber or the outside of the panel. The basalt material offers an outerreinforcement that can be strengthened by the existing panels withmodifications.

The production vehicle can have a built in roll cage system of basaltmaterial built in the panels, and up from the frame system. The basaltreinforced panels offer the build of modular structures for easyassembly of vehicle. The basalt material can have color mixed it theassemblies to offer colored panels. The basalt fiber may be mixed inwith epoxy and or glue that adheres to metals and can also offer a classA surface. The resin basalt mixture can also be painted and repaired inmuch the same fashion as fiber glass.

According to one embodiment the disclosure provides a method ofmanufacturing a vehicle component. For example, the method may includethe step of providing a vehicle panel Basalt fibers are mixed with acarrier, such as epoxy or glue. This mixture of basalt fibers and epoxyor glue is applied to the vehicle panel. For example, in someembodiments, the application could be done by spraying the mixture ofbasalt fibers and epoxy or glue to the vehicle panel. In some cases, thebasalt fibers are chopped into segments that are mixed with a heatcuring glue. For example, the basalt fibers are mixed with a heat curingglue at approximately 320° F. for approximately twenty minutes. Thisallows the vehicle panel to be dried at an ambient temperature. In someembodiments, a mixture of approximately 70 percent basalt fibers and 30percent glue or epoxy by volume could be used. If it is desirable forthe component to be colored, a color additive could be added to the glueor epoxy mixture. This could be used to reinforce a number of differentareas in the vehicle, such as an inner surface or outer surface of astamped panel. Embodiments are contemplated in which one or more cornersof a roll cage could be reinforced using basalt fibers.

Additional features and advantages of the invention will become apparentto those skilled in the art upon consideration of the following detaileddescription of the illustrated embodiment exemplifying the best mode ofcarrying out the invention as presently perceived. It is intended thatall such additional features and advantages be included within thisdescription and be within the scope of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will be described hereafter with reference to theattached drawings which are given as non-limiting examples only, inwhich:

FIG. 1 is an exploded view of an example strand of pultruded basaltfiber;

FIG. 2 illustrates an example of conventional method of sprayapplication of basalt fiber and resin;

FIGS. 3 and 4 provide examples of stamped panels reinforced with basaltaccording to one embodiment of the invention;

FIG. 5 provides an example roll cage assembly reinforced with basaltaccording to one embodiment of the invention;

FIG. 6 shows a joint where the basalt rods are joined according to oneembodiment of the invention; and

FIGS. 7, 8 and 9 illustrate an example embodiment for testing thestrength of a B pillar reinforced with basalt.

Corresponding reference characters indicate corresponding partsthroughout the several views. The components in the figures are notnecessarily to scale, emphasis instead being placed upon illustratingthe principals of the invention. The exemplification set out hereinillustrates embodiments of the invention, and such exemplification isnot to be construed as limiting the scope of the invention in anymanner.

DETAILED DESCRIPTION OF THE DRAWINGS

While the concepts of the present disclosure are susceptible to variousmodifications and alternative forms, specific exemplary embodimentsthereof have been shown by way of example in the drawings and willherein be described in detail. It should be understood, however, thatthere is no intent to limit the concepts of the present disclosure tothe particular forms disclosed, but on the contrary, the intention is tocover all modifications, equivalents, and alternatives falling withinthe spirit and scope of the disclosure.

According to one embodiment a basalt material may be mixed with epoxy orglue to offer a strength reinforcement that is proportional to themixture of the fiber with the carrier of epoxy or glue. Variousembodiments are contemplated for applying the fiber to a stamped panel.The basalt material could be used in the same way as fiberglass andepoxy for build and repair. The application of a basalt fiber/epoxymixture can be sprayed on in operation, which offers a rapid covering ofa stamped panel. This is a primary candidate for operations requiringrapid production.

In one embodiment, chopped fiber may be added into heat curing glue. Forexample, glue or epoxy could be used in the production of an automotivepanel. The use of a heat curing adhesive with the woven fiber of basaltcould be performed by die cutting and attaching the fiber with epoxy orheat cured glue making stronger lighter panels. FIG. 2 provides anexample spray application of basalt fiber and resin.

The basalt woven fiber could be die cut and placed into position andadhesively attached or epoxy attached. For example, in one embodiment,the basalt fiber could be mixed with a heat cured glue at 320 Degrees F.for 20 Min. The epoxy is the preferred method of adhesion, because itwill dry in the ambient temperature and still be able to pass throughthe heat ovens without degrading.

In another embodiment, basalt fiber is mixed with glue that is rated tothe level to hold metal together. This method works well but the partsmust be clamped in place until the assembly passes through the paintoven and cures the glue. This is in some cases a costly process. In thisprocess the glue becomes as strong as the metal it is attached to andthe basalt fiber used in the mix of the glue 70% fiber long or shortfiber per operation and 30% glue, or epoxy. This mix works well in themanufacture operation.

Basalt used the construction of automotive parts offers a lot ofpositive attributes to the process. The basalt can be attached to astamped panel on the inside offering strength and being invisible to thecustomer. This will achieve far stronger panels that are lighter thansteel. If the basalt is attached to the outside of the panel the epoxycan be developed into a class A, first surface panel offering strengthand color can be added to the epoxy or glue. The basalt can be added tothe inner and outer surface of stamped panel adding strength and with aminimum of support stamped steel.

FIG. 3 shows an example of basalt fibers applied to the outside of astamped panel. The basalt fiber placed on the outside of a stampedpanel's offers strength, a class A surface and color can be added to theepoxy or glue. The basalt can be a mixed formula of basalt fiber andepoxy or glue sprayed on to the base stamping. Another option is to laythe woven fibers onto the stamped panel using epoxy or heating curingadhesive. The panel can be painted after the epoxy or glue is dried.

FIG. 4 shows a reinforcement of the steel stamped panel with thecontinuous fiber basalt. In this example, the basalt is placed in thecorners of the “B” pillar as a mixture of continuous fiber and epoxy orglue. A second alternative is to use multiple layers of the basalt wovenfibers, which would be placed in the contour of the stamped panel andpressed in place. In this operation, an anaerobic fermentation processwould be used where the epoxy is injected into the die and the airvacuumed out for a quicker turnaround time.

A roll cage could be build according to one embodiment starting from theframe and using the stamped panels reinforced with basalt fiber. Thisprocess would build a complete roll cage system offering protection forthe passengers without the sacrificing the design of the vehicle. Therehave been several joints designed to pull the roll cage together thejoints will bring the basalt reinforcement together and be adhesivelyjoined or glued. In the case of the top of the “B” pillar of thevehicle, according to one embodiment, there will be a joint that joinsfive support stampings together to offer a very strong joint in a keylocation. The other joints are corners to offer strength and lend to amodular build of the side frames and, roof and frame. This is a processthat will eliminate several welding operations and lend to the modularconstruction of a vehicle.

FIG. 5 shows a structured roll over cage that will be fastened to thepanels. With this design, all of the panels come together into a jointat joints (See FIG. 6) and creating a built in roll cage in theproduction vehicle. This offers a stronger structure with little addedweigh and parts. We are simply modifying the existing panels by addingthe basalt for strength in manufacturing. The assembly of the panels canresult into a modular construction with an easy assembly operation. Thestructure extends upward from the frame and across the roof and sides ofthe vehicle creating a roll cage to protect the inside in a very strongstructure.

FIG. 6 shows an example joint where the basalt rods are joined. Thereare several possible joints to be designed in the roll cage assembly.The basalt rod or structure is placed into a joint sleeve. As the basaltrod or structure is placed into the outer joint assembly it passes aseries of one way lock tabs. The purpose of the tabs is to provide a oneway lock to hold the parts together until the adhesive takes effect.When all the basalt rods or structure are placed into the joint sleeves,there is epoxy or glue injected into the assembly to harden and make theassembly very strong. The rod or structure has a pointed end that fitsinto a valley in the other rods or structure. One purpose of this designis to make a solid attachment of the parts.

FIGS. 7, 8 and 9 show an example prototype for testing how to make areinforced “B” pillar. The “B” pillar is a critical section that is cutout of the “B” pillar stamping. In this local area, the crush is mostlikely to occur in a roll over crash. For the test, this location hasbeen isolated as our test area is the worst case. The B pillar is cutoff at top from Line A and at the bottom Line B(1). The entire series of“B” pillar are all the same and laser cut to his exact position. Bypreparing the B pillar panels in this manner we have a common comparisonto determine the materials to use and how much material to use to batchthe Boron “B” Pillar in use today. This will give us common base tocompare for strength.

In FIG. 7 is shown a method to determine the amount of basalt continuousfiber (2) to apply to the strengthening of the B pillar section (1). Thetarget of continuous fiber estimated needed is based on a 1″ diameter ofBasalt re-rod (3) for which we have test data on. (Stork MaterialTechnology 25 mm Diameter average yield strength 0.2% psi=62,200 or43161.2 n/cm̂2 and Average tensile Strength, psi=68,600 or 47,298.04n/cm̂2). In using this data as a starting point, we are planning to lineeach side of the B pillar test panel (1) with the equal amount of 1″diameter or basalt continuous fiber (2). The 1″ basalt fiber re rod (3)has a 140 continuous fibers (2) running parallel through it from end toend. When epoxy or glue is added to the fiber, the mixture becomes verystrong and when attached to the B pillar test panel (1) it reinforcesthe panel many fold over per testing evaluation. By wrapping the basaltre rod around the B test pillar 140 times we have the equal amount ofthe basalt 1″ re-rod (3) equal 4800 tex from 24 cakes this 115200continuous fibers (2) coming together to make the reinforcement of the Bpillar test panel (1) one layer on each side is shown a method todetermine the amount of basalt continuous fiber (2) to apply to thestrengthening of the B pillar section (1). The basalt continuous fiber(2) is placed in the corners of the B pillar test panel (1) and aninternal mold (6) is built with cavities for the basalt continuous fiber(2) and layer basalt woven fiber (7). The basalt woven fiber (7) is laidover the basalt continuous fiber (2) with a mixture of epoxy or glue andthe internal mold (6) forces out the excess epoxy or glue and forces thematerial hard against the inside walls of the B pillar test panel (1).There is an anaerobic process used to remove the air and accelerate thehardening of the epoxy or glue.

According to another embodiment, the basal woven fiber (7) is used muchthe same way as a fiberglass operation can be used. The difference beingthat it is many times stronger when finished. We are contemplating thatthis may replace a roof panel made from carbon fiber. The basalt fiberis in a close range to carbon fiber but less expensive and near the samestrength and looks the same as carbon fiber. In the manufacture ormolding of panels the anaerobic process is used with epoxy and glue as ahardening agent. A roof made of carbon fiber is dangerous and will notpass the roll over tests. Carbon fiber is glass filled and shatters whenit reaches its breaking point. Basalt per strand is a rock fiber andbreaks, but does not shatter. Basalt is close to the strength of carbonfiber and less expensive. Carbon fiber has a lengthy production processand on a mass production scale carbon fiber could the meet the demands.Basalt is the most abundant material around and can be manufactured withlittle loss. If you wanted to produce a ton of basalt fiber, you use oneton of basalt rock. There are no additives or losses. This is not thecase of steel and carbon fiber.

In FIG. 8 is shown a method to determine the amount of basalt choppedfiber (8) to apply to the strengthening of the B pillar section (1). Thebasalt chopped fiber (8) is sprayed onto the B pillar test panel (1).The basalt continuous fiber (2) is placed in the corners of the B pillartest panel (1) and an internal mold (6) is built with cavities for thebasalt continuous fiber (2) and layer basalt woven fiber (7). The basaltchopped fiber (8) is sprayed over the basalt continuous fiber (2) with amixture of epoxy or glue and the internal mold forces out the excessepoxy or glue and forces the material hardening against the inside wallsof the B pillar test panel (1). There is an anaerobic process used toremove the air and excel the hardening of the epoxy or glue.

In FIG. 9 is shown a method of fastening the basalt re-rod (9) into thecorners of the B pillar test panel (1). The re-rod (9) will be gluedwith epoxy or glue to the B pillar test section (1) till the time thatit becomes attached to the B pillar test panel (1). We know the tensilestrength of the re-rod from the Stork Test data. Because the 1″ diameterre-rod (3) cannot be bent we will have to test with lesser diameterre-rod samples. We are looking at possibly 12 mm, 8mm or 6 mm forpurposes of testing because we have re-rod and Stork test data on thesesizes. This test is to determine what level of strength we need tocompete with the market of (roll over test 4×the vehicle body weight).If we need to obtain more strength we can overlay the re-rod (9) withbasalt woven fiber number of layer (7) or spray basalt chopped fiber (8)onto the assembly.

Basalt fiber has great strength can be attached to existing stampedpanels or plastic panels. In this way we can bring a strong panel to themarket. The attaching of the basalt offers an opportunity in themanufacturing industry. The basalt fiber if mixed with an adhesive canbe used as a way of attaching panels and also building strength into thepanels. In some cases this may require heating the adhesive until itcures. In other cases, the adhesive can be cured in ambient temperature.Whatever the attachment method chosen, the basalt fiber is mixed intothe adhesive serves to strengthen the panels. The basalt fiber can bechopped into small fibers such as 13 micron to 3 mm long and mixed intothe adhesive. The fiber can also be used as a continuous filament of thefiber that is placed axial into the corners of a panel offeringstrength.

The continuous strand fibers are somewhat awkward in the rapid assemblyoperation because of the time to place them into the proper place andcure them until hardened. This is an operation that we would have tomove to an area that would pre mold up the reinforced panels ahead ofthe assembly operation with a reasonable time of set up. When thereinforcement panels are cured up, they are added to the assemblyoperation. The continuous fiber is placed into the desired position andthen a die is placed into the area and holds the materials in placeuntil the time they have cured. An example would be a hat section panelwith the basalt placed into the corners. The next operation would be fora die would be placed in the hat section holding the continuous fiber inplace and squeezing the excess epoxy or glue out. The die would bemolded of a releasing agent to prevent the epoxy or glue from attachingto it as well. In this manner the continuous fiber and the epoxy or gluewill attach itself to the hat section and when cured the hat sectionwill be stronger.

The attachment of panels together with the use of adhesive is known inthe industry. The adhesive has glass balls added to it to keep thepanels a few microns apart and allow the adhesive to cure up withoutbeing squeezed out of the targeted area. By adding the basalt fibersinto the adhesive, we are serving the same purpose but also adding thestrength of the basalt fiber to joint. This would also eliminate theneed for the glass balls to separate the panels. The adhesive company'sadvertise the glass balls off as a means of separating panels toeliminate the electrical effect between two dissimilar metals such asaluminum and steel. The basalt material does not conduct electricalcurrent so it would be an excellent spacer and strengthener for the usein joining panels together. Basalt is not only strong but it has aresistance to electricity and can be used in the manufacture of housingand for electrical equipment such as modules.

In the making of a basalt panel with a class A surface we can pre moldsheets of bi axle fabric basalt with +45 degrees/−45 degree orientation,so tri axial fabric with 0 degree/+45 degree/−45 degree strands, andalso 4 axis 0 degree, 90 degree +45/−45 degree in a pre-mold process inthe shape needed. We can add a layer of fiber that is a layer of choppedstrand mat, similar to a glass mat used for fixing boats. This mat canbe fixed to a layer of woven fiber or sheet layers this will give amultiple layer assemble that is molded to one part. The constructionwill build up the laminate thickness quicker than you can with multiplelayers of fabric. Using this process, we can mold panels that are strongand can have a class A surface. This can be used to make car panel likehoods fenders, truck cabs, and train cover panels.

The basalt fiber has a high temperature resistance and good lightresistance. The basalt material in the woven type can very easily beadapted to vehicle interiors as fire resistant fabrics and as well asclothing. The clothing can be used for firefighters etc. To myknowledge, the automotive industry has not used basalt as astrengthening agent in the build of a vehicle. In the manufacture ofbasalt if you melt and pour basalt, it will form a glass if quicklycooled. Knowing this we can melt and pour basalt into a mold and using agradual cooling process. If you cool it slow enough you will reform abasalt rock in the needed shape. In doing this operation we cantransform the basalt material into another form as we need it. In usingthis process we can achieve many different shapes as in sand casting. Ifit was desired to form a panel with honeycomb reinforcement behind itthe forming method would be much like a large waffle iron. This is inthe case of a hood or door panel or other like panels.

Although the present disclosure has been described with reference toparticular means, materials, and embodiments, from the foregoingdescription, one skilled in the art can easily ascertain the essentialcharacteristics of the invention and various changes and modificationsmay be made to adapt the various uses and characteristics withoutdeparting from the spirit and scope of the invention.

What is claimed is:
 1. A method of manufacturing a vehicle component,the method comprising the steps of: providing a vehicle panel; mixingbasalt fibers with a carrier that includes one or more of an epoxy or aglue; and applying the mixture of basalt fibers and epoxy or glue to thevehicle panel.
 2. The method of claim 1, wherein the applying step isperformed by spraying the mixture of basalt fibers and epoxy or glue tothe vehicle panel.
 3. The method of claim 1, wherein the basalt fibersare chopped into segments that are mixed with a heat curing glue.
 4. Themethod of claim 3, further comprising the step of drying the vehiclepanel at an ambient temperature.
 5. The method of claim 4, wherein thebasalt fibers are mixed with a heat curing glue at approximately 320° F.for approximately twenty minutes.
 6. The method of claim 1, furthercomprising the step of temporarily clamping one or more vehiclecomponents of an assembly together prior to the applying step, furthercomprising the step of passing the assembly through an oven to cure theglue.
 7. The method of claim 1, wherein the mixing step is performed byusing approximately 70 percent basalt fibers and 30 percent glue orepoxy by volume.
 8. The method of claim 7, further comprising the stepof adding a color additive to the glue or epoxy mixture.
 9. The methodof claim 1, wherein the vehicle panel is a stamped panel and the mixtureis added to one of an inner or outer surface of the stamped panel. 10.The method of claim 1, wherein the mixture is applied in one or morecorners of a B pillar of a vehicle.
 11. A vehicle component formed by aprocess comprising the steps of: providing a vehicle panel; mixingbasalt fibers with a carrier that includes one or more of an epoxy or aglue; and applying the mixture of basalt fibers and epoxy or glue to thevehicle panel.
 12. The method of claim 11, wherein the applying step isperformed by spraying the mixture of basalt fibers and epoxy or glue tothe vehicle panel.
 13. The method of claim 11, wherein the basalt fibersare chopped into segments that are mixed with a heat curing glue. 14.The method of claim 13, further comprising the step of drying thevehicle panel at an ambient temperature.
 15. The method of claim 14,wherein the basalt fibers are mixed with a heat curing glue atapproximately 320° F. for approximately twenty minutes.
 16. The methodof claim 11, further comprising the step of temporarily clamping one ormore vehicle components of an assembly together prior to the applyingstep, further comprising the step of passing the assembly through anoven to cure the glue.
 17. The method of claim 11, wherein the mixingstep is performed by using approximately 70 percent basalt fibers and 30percent glue or epoxy by volume.
 18. The method of claim 17, furthercomprising the step of adding a color additive to the glue or epoxymixture.
 19. The method of claim 11, wherein the vehicle panel is astamped panel and the mixture is added to one of an inner or outersurface of the stamped panel.
 20. The method of claim 11, wherein themixture is applied in one or more corners of a B pillar of a vehicle.